Method for producing at least one disc or ring disc -shaped component and machining centre

Abstract

A method is proposed for manufacturing at least one disc- or ring-shaped component (2), in particular a disc- or ring-shaped wheel, characterized by the steps of: - providing at least one blank (1) having a central axis (ZA) and requiring mechanical machining, in particular by cutting; - arranging or clamping the blank (1) in at least one clamping situation (AS) in which the central axis (1) of the blank (1) is perpendicular to a vertical axis (VA); - machining the clamped blank (1) mechanically, in particular by cutting, to manufacture the disc- or ring-shaped component (2). A machining center is also proposed.

Description

[0001] The invention relates to a method for producing at least one annular disc-shaped component in the form of a wheel having a hub for a rail vehicle.

[0002] Corresponding processes for the production of ring-disk-shaped components, ie ring-disk-shaped wheels, such as those used as wheels for rail vehicles or railway wheels, are known per se from the state of the art.

[0003] Corresponding methods typically comprise the provision of a ring-disk-shaped blank to be machined, which is clamped in a clamping situation and is machined mechanically, ie in particular by machining, in this clamping situation to form the component to be manufactured.

[0004] To date, the blank in the clamping situation has typically been arranged or aligned in such a way that its symmetry or central axis lies in a vertical axis or plane.

[0005] This clamping situation can result in various disadvantages, which, for example, consist in or result from the accumulation of material removal, i.e. in particular chips, and / or coolant on the blank to be machined, which can have a negative effect on the machining process.

[0006] US 2012 / 0319364 A1, US 2005 / 120557 A1 and US 2006 / 042091 A1 each disclose a method for producing a motor vehicle rim.

[0007] GB 752 088 A, DE 20 2011 103 889 U1 as well as US 1 759 098 A and US 1 552 770 A each disclose a method for manufacturing a railway wheel.

[0008] The invention is based on the object of specifying a method which is improved compared to the method for producing at least one annular disc-shaped component in the form of a wheel having a hub for a rail vehicle.

[0009] The object is achieved by a method according to claim 1. The dependent claims relate to possible embodiments of the method.

[0010] The method described herein serves to produce at least one (essentially) annular disc-shaped component in the form of a wheel having a hub for a rail vehicle, e.g., a drive wheel for rail vehicles.

[0011] The component to be manufactured may, under certain circumstances—i.e., depending on the specific intended application of the component—have a geometry that deviates from a geometrically defined annular disc-shaped geometry. Such deviations may, for example, consist of a stepped contoured design of the outer circumference, as is found, for example, in railway wheels.

[0012] The method according to the invention comprises the steps according to claim 1.

[0013] In a first step of the method, at least one blank to be machined mechanically, i.e., within the scope of the invention, by cutting, is provided. The blank has a central axis. The central axis can be, for example, an axis of symmetry of the blank. The blank has a rotationally symmetrical, i.e., an annular disk-shaped, geometry. The annular disk-shaped blank has a disk plane. The disk plane is typically penetrated by the central axis of the blank at a right angle; the central axis of the blank is therefore typically aligned perpendicular to the disk plane of the blank.

[0014] The blank or at least the annular disc-shaped component to be produced according to the invention can have sections having different cross-sectional geometries or surfaces. For example, the blank or the component to be produced can have a different cross-sectional geometry in the area of ​​the outer circumference than in areas further inside, viewed radially. For the inventive production of a wheel, in particular a railway wheel, the outer circumference of the machined blank forms a later running surface of the component. Typically, a metallic blank, i.e. a blank made of a metallic material, e.g. an iron-based one, is provided; accordingly, the annular disc-shaped component to be produced is a metallic component, i.e. a component made of a metallic material, e.g. an iron-based one. The blank is in particular a semi-finished product.Specifically, the blank can be a metallic casting or forging, i.e. a blank made of a metallic casting or forging alloy.

[0015] A correspondingly provided blank to be machined is clamped in a second step of the method following the first step in at least one clamping situation, i.e., in particular, a clamping position or clamping orientation of the blank (hereinafter, only the term "clamping situation" is used, which includes a specific clamping position or clamping orientation of the blank). Each clamping situation of the blank is correlated with at least one specific machining situation of the blank, i.e., a machining position or machining orientation of the blank (hereinafter, only the term "machining situation" is used, which includes a specific clamping position or clamping orientation of the blank).

[0016] According to the invention, the blank is clamped in at least one clamping situation in which the central axis of the blank is at an angle to a vertical axis or plane; the central axis of the blank thus lies (apart from a possible intersection point) outside a vertical axis or plane. The blank to be machined is therefore arranged in the clamping situation such that the central axis of the blank is at an angle to a vertical axis or plane, i.e. not parallel to a vertical axis or plane. For a ring-disk-shaped blank, the disc plane of the blank is or becomes oriented at an angle to a horizontal axis or plane in the clamping situation; as will be seen below, the disc plane of the blank can be or become oriented in particular parallel to a vertical axis or plane in the clamping situation.

[0017] The angularly inclined or tilted arrangement or orientation of the blank relative to the vertical axis or plane - this can be defined, for example, by a vertical machine axis of a machining center used to carry out the process - results in a number of advantages for the mechanical machining of the blank and thus for the production of the ring-disk-shaped component to be manufactured. These advantages consist, in particular, in the fact that an accumulation of material removal, i.e. in particular chips, and / or coolant on the blank to be machined is made more difficult or even impossible, depending on the specific orientation of the blank relative to the vertical axis. This also means that the cooling effect and thus the efficiency of the cooling of the blank during its mechanical machining can be (significantly) improved, compared to the typically used coolant, which is only difficult or impossible.cannot accumulate on the blank at all, i.e., for the annular disk-shaped blank, in particular on a blank surface parallel to a disk plane, and heat up there. Furthermore, the mechanical machining process of the blank can be better observed (optically), thus resulting in advantages with regard to process monitoring that is to be implemented or has been implemented. These advantages exist in particular compared to a conventional clamping of the blank in a clamping situation in which the central axis of the blank lies in a vertical axis or plane.

[0018] The blank is clamped in the clamping situation described using a clamping device, e.g. a chuck, of a machining center used to carry out the method, said clamping device comprising one or more clamping elements, i.e. a plurality of clamping jaws. The clamping device or clamping devices used are therefore designed to clamp the blank in the clamping situation described. A corresponding clamping device can also be designed to realize a plurality of different clamping situations in which the central axis of the blank is at an angle to a vertical axis or plane. A corresponding clamping device can be movably mounted in at least one degree of freedom of movement - this can be a translational degree of freedom of movement along at least one translation axis and / or a rotational degree of freedom of movement about at least one rotation axis.A corresponding translation or rotation axis can, for example, be defined by a machining or machine axis of a machining center used to carry out the process.

[0019] In a third step of the process following the second step, the blank is clamped in the clamping situation(s) in which the central axis of the blank is at an angle to the vertical axis or plane and is then mechanically machined to produce the annular disk-shaped component. The mechanical machining of the blank is based in particular on data relating to the final geometry of the component to be manufactured, so that the component is manufactured with a near-net shape or with an exact net shape. The mechanical machining of the blank comprises at least one machining or cutting mechanical machining step. The mechanical machining of the blank is carried out at least by turning and / or milling, and optionally supplemented by drilling.

[0020] The mechanical machining of the blank is carried out using at least one mechanical machining device comprising at least one mechanical machining tool, i.e., at least one turning and / or milling tool, and optionally additionally a drilling tool. Depending on the specific design, the mechanical machining device can be movably mounted relative to the blank clamped in the clamping situation with at least one degree of freedom of movement—this can be a translational degree of freedom of movement along at least one translation axis and / or a rotational degree of freedom of movement about at least one rotation axis.

[0021] Overall, there is an improved process for producing a ring-disk-shaped component.

[0022] According to the invention, the angle between the blank clamped in the respective clamping situation and the vertical axis or plane is between 80 and 100°, in particular between 85 and 95°.

[0023] According to a specific embodiment of the method, the blank can be clamped such that its central axis is aligned at an angle of 90° relative to the vertical axis or plane. The central axis of the blank can thus be aligned horizontally in the clamping situation. The central axis of the blank can thus be aligned coaxially or concentrically with a machining axis of a machining center used to carry out the method. The disk plane of an annular disk-shaped blank can thus be aligned vertically in the clamping situation.

[0024] The angles or angle ranges mentioned above can be understood as clockwise or counterclockwise.

[0025] In a first or a second clamping situation, a complete mechanical machining of a surface of the blank lying parallel to a central plane, i.e. for a ring-disk-shaped blank parallel to a disk plane, i.e. for example an upper or lower side of the blank, is carried out. Such mechanical machining means axial mechanical machining of the blank with respect to a ring-disk-shaped geometry of the blank, so that a ring-disk-shaped blank is provided, in particular by turning, e.g. with through holes or blind holes axially penetrating it, to form a hub of the component to be manufactured. In addition, such mechanical machining can mean radial mechanical machining of the blank with respect to a ring-disk-shaped geometry of the blank, so that a ring-disk-shaped blank is provided, for example, with radially extending, in particular annular, depressions.A hub of the component to be manufactured is also formed in this way. A targeted modification of the cross-sectional geometry of the blank is possible.

[0026] Furthermore, in the first clamping situation, a complete mechanical machining of the outer circumference of the blank takes place, i.e. for the ring-disk-shaped blank, a lateral surface of the blank forming the outer circumference. Such machining means axial machining of the blank (relative to the central axis of the blank) with regard to a ring-disk-shaped geometry of the blank, so that a ring-disk-shaped blank is provided with a specific outer circumferential contour forming the running surfaces of a wheel to be manufactured by turning and / or milling. By mechanically machining the blank clamped in the clamping situation, the outer contour or the lateral surface of the ring-disk-shaped component to be manufactured is therefore (also) machined, i.e. the area of ​​the running surfaces of a wheel to be manufactured. Here, too, a targeted change to the cross-sectional geometry of the blank is possible.

[0027] In the first clamping situation, the blank is clamped by clamping elements that engage a section of the blank's inner diameter, which may be axially shoulder-like, protruding, or recessed, e.g., like a bore. Clamping jaws that engage the inner diameter or a corresponding surface are used as clamping elements for clamping the blank. In particular, several clamping jaws evenly distributed around the circumference can be used. The clamping jaws can be arranged in such a way that centering of the blank is possible.

[0028] In the first clamping situation, in which both a surface of the blank lying parallel to a central plane, i.e. for a ring-disk-shaped blank parallel to a disk plane, i.e. e.g. an upper or lower surface of the blank, and a mechanical machining of the outer circumference of the blank take place, non-machinable or machinable sections of the blank can also be mechanically machined after a rotating or turning movement of the sectionally mechanically machined blank. The sectionally mechanically machined blank can therefore be moved, rotated or turned out of the clamping situation after mechanical machining in the clamping situation - this is particularly a 180° rotation or turning - and moved back into the (same) clamping situation and clamped again in order to then machine the remaining gates that have not yet been mechanically machined.The blank can then be clamped on the opposite section of the blank; when the blank is clamped again, the clamping elements engage on the opposite section of the blank in the clamping situation compared to the first or previous clamping in the clamping situation.

[0029] For this purpose, suitable handling of the sectionally machined raw part may be required, which can be realized, for example, via a handling device, ie in particular a robot device.

[0030] The blank can also be clamped in several different clamping situations, in particular with regard to the respective spatial orientation of the blank, i.e. in particular arranged or spaced differently locally or spatially, i.e. at least in a first clamping situation and in a second clamping situation. Each clamping situation is characterized in that several clamping jaws of at least one clamping device act on a section of the blank, forming a clamping of the blank. In this case, the blank is clamped in respective clamping situations such that the central axis of the blank is at an angle, i.e. in particular at right angles, to the vertical axis or plane.

[0031] Regardless of the specific clamping setup and the resulting spatial orientation of the blank relative to the vertical axis or plane, as mentioned above, every clamping situation involves machining a specific, particularly exposed and thus machineable, section of the blank. Each clamping situation therefore typically correlates with a specific machining situation of the blank.

[0032] According to the invention, a complete mechanical machining of a surface of the blank lying parallel to a central plane, i.e. for a ring-disk-shaped blank parallel to a disk plane, i.e. for example an upper or lower side of the blank, is carried out, for which the blank is clamped in a first clamping situation or in a second clamping situation which differs from the first clamping situation. Such mechanical machining comprises a mechanical machining of the blank which takes place axially with regard to a ring-disk-shaped geometry of the blank, whereby a hub is formed. In addition, such mechanical machining can mean a mechanical machining of the blank which takes place radially with regard to a ring-disk-shaped geometry of the blank, so that a ring-disk-shaped blank is provided, for example, with radially extending, in particular annular, depressions.In all cases, a targeted change in the cross-sectional geometry of the blank is possible.

[0033] According to the invention, the blank is clamped in a first clamping situation in which a complete mechanical machining of the outer circumference of the blank, i.e. for a ring-disk-shaped blank, a lateral surface of the blank forming the outer circumference, takes place. Such machining includes machining of the blank axially (relative to the central axis of the blank) with respect to a ring-disk-shaped geometry of the blank, so that a ring-disk-shaped blank is provided with a specific outer circumferential contour forming the running surfaces of a wheel to be produced by turning and / or milling. By mechanically machining the blank clamped in the first clamping situation, a machining of the outer contour or the lateral surface of the ring-disk-shaped component to be produced, i.e. the area of ​​the running surfaces of a wheel to be produced, takes place.Here too, a targeted change in the cross-sectional geometry of the blank is possible in all cases.

[0034] In the first exemplary clamping situation, the blank is clamped using clamping elements that engage a section of the inner diameter of the blank, which may be axially protruding, shoulder-like, or recessed, e.g., like a bore. Clamping jaws that engage the inner diameter or a corresponding surface are used as clamping elements for clamping the blank in the first clamping situation. In particular, several clamping jaws arranged evenly distributed around the circumference can be used. The clamping jaws can be arranged in such a way that centering of the blank is possible in the first clamping situation.

[0035] In an alternative to the invention, the blank can be clamped in a second clamping situation via clamping elements engaging the outer circumference of the blank. Correspondingly, the annular disk-shaped blank is clamped in the second clamping situation via clamping elements engaging a peripheral surface forming the outer circumference. Clamping jaws engaging the outer circumference or a peripheral surface forming the outer circumference are used as clamping elements for clamping the blank in the second clamping situation. In particular, several clamping jaws evenly distributed around the outer circumference can be used. The clamping jaws can be arranged in such a way that centering of the blank is possible in the second clamping situation.

[0036] A blank can thus be clamped and machined in several different clamping situations, possibly arranged opposite one another. Each clamping situation is correlated with a specific machining situation, i.e., in particular, a specific machining step. As mentioned, in each clamping or machining situation, the exposed sections of the clamped blank can be machined.

[0037] Accordingly, the blank can be transferred, for example, from a first clamping situation in which the central axis of the blank to be machined lies at an angle to the vertical axis or plane, into at least one further clamping situation in which the central axis of the blank to be machined lies at an angle to a vertical axis or plane. The respective clamping situations can be opposite one another. This opens up the possibility, described in more detail below, of providing several blanks and machining them at least partially simultaneously. Thus, several blanks to be machined having a central axis can be provided and machined to form respective annular disk-shaped components to be produced.As will be shown below, the mechanical processing of the respective components can be carried out at least partially simultaneously; this results in positive aspects for the efficiency and productivity of the process.

[0038] It is possible, for example, for a first blank to be machined to be initially clamped in a first clamping situation in which the central axis of the first blank is at an angle to the vertical axis or plane, and then to be machined in a first mechanical machining step in the first clamping situation. After completion of the first mechanical machining step, the first blank, which has already been machined in sections, can be transferred to a second clamping situation (different from the first clamping situation) in which the central axis of the first blank is again at an angle to the vertical axis or plane.

[0039] plane, transferred, clamped in this plane and then transferred for mechanical processing in a second mechanical processing step. A further blank to be machined can be clamped during or after clamping of the first blank in the second clamping situation in the first clamping situation in which the central axis of the further blank is at an angle to the vertical axis or plane, and then mechanically machined in a first mechanical processing step in the first clamping situation. After completion of the first mechanical processing step, the further blank that has already been machined in sections can be transferred to the second clamping situation or a second clamping situation in which the central axis of the further blank is again at an angle to the vertical axis or plane, clamped in this plane and then mechanically machined in a second mechanical processing step.This typically only occurs - provided the second clamping situation is the second clamping situation in which the first blank is subjected to the second mechanical machining step - when the first blank has left the second clamping situation, i.e. the second mechanical machining step of the first blank in the second clamping situation has been completed. Consequently, sequential mechanical machining of several blanks in several clamping situations, i.e. machining of several blanks in several clamping situations one after the other, can take place. The second mechanical machining step of the first blank can take place at least partially at the same time as the first mechanical machining step of the other blank (and vice versa). The principle can be extended to more than two clamping situations and correspondingly more than two mechanical machining steps correlated with them.

[0040] Furthermore, it is possible for a first blank to be machined to first be clamped in a first clamping situation in which the central axis of the first blank is at an angle to the vertical axis or plane, and for the blank to be machined in a first mechanical processing step in the first clamping situation. After completion of the first mechanical processing step, the blank that has already been machined in sections can be transferred to a second clamping situation in which the central axis of the first blank is again at an angle to the vertical axis or plane, clamped in this second clamping situation and then machined in a second mechanical processing step. A further blank to be machined can first be clamped in the second clamping situation in which the central axis of the second blank is again at an angle to the vertical axis or plane.plane, and mechanically machined in a first mechanical machining step in the second clamping situation. After completion of the first mechanical machining step of the first blank in the first clamping situation and after completion of the first mechanical machining step of the further blank in the second clamping situation, the first blank can be moved to the second clamping situation in which the central axis of the first blank is angled to the vertical axis orplane, is transferred, clamped in this and mechanically machined in a second mechanical machining step, and after completion of the first mechanical machining step of the further blank in the second clamping situation and the first mechanical machining step of the first blank in the first clamping situation, the further blank is transferred to the first clamping situation, in which the central axis of the further blank lies at an angle to the vertical axis or plane, clamped in this and mechanically machined in a second mechanical machining step. Thus, simultaneous mechanical machining of the blanks can take place in respective clamping situations. The blanks machined in respective first machining steps can then swap their respective first clamping situations and, after clamping in respective second clamping situations, can be subjected to respective second mechanical machining steps.The first machining step of the first blank can thus be performed simultaneously with the first machining step of the second blank. The second machining step of the first blank can also be performed simultaneously with the second machining step of the second blank. The principle can be extended to more than two clamping situations and, accordingly, more than two associated machining steps.

[0041] In all cases, at least one machining device can be assigned to each clamping situation. The machining device assigned to the respective clamping situation is configured to perform a mechanical machining operation on the clamped blank to be carried out in the respective clamping situation or the machining situation correlated therewith. For this purpose, the machining device assigned to the respective clamping situation can be movably mounted relative to the blank clamped in the respective clamping situation in at least one degree of freedom of movement - this can, as mentioned, be a translational degree of freedom of movement along at least one translational axis and / or a rotational degree of freedom of movement about at least one rotational axis.In principle, however, it is also conceivable, alternatively or additionally, for the blank clamped in the respective clamping situation to be mounted so as to be movable in at least one degree of freedom of movement, i.e., a degree of freedom of movement along a translation axis and / or about a rotation axis, relative to the mechanical processing device associated with the respective clamping situation; as mentioned above, a clamping device can also be movable in at least one degree of freedom of movement.

[0042] The transfer of a blank, possibly already machined, from a first clamping situation to a second or at least one further clamping situation (or vice versa) can take place in a specific transfer position in which a transfer or handover of a blank from a first clamping situation to at least one further clamping situation (or vice versa) is possible. A blank, possibly already machined, to be transferred from the first clamping situation to a further clamping situation (or vice versa) can thus be moved to a corresponding transfer position—this can be arranged, for example, between the two clamping situations.

[0043] The transfer of a blank, possibly already mechanically machined, from a first clamping situation to a second or at least one further clamping situation (or vice versa) can be carried out via a handling device, comprising one or more handling elements, i.e., e.g., one or more gripper elements, i.e., e.g., a handling robot, of a machining center used to carry out the method. The or a handling device used is thus configured to transfer a blank, possibly already mechanically machined, from a first clamping situation to at least a second or at least one further clamping situation (or vice versa). A corresponding handling device can be designed as a gripper device comprising at least one gripper element or at least comprise one such gripper. A gripper device can, for example, be designed as a (multi-axis) gripper robot.

[0044] As can be seen from the above, the process can be carried out in a machining center for machining (metallic) workpieces.

[0045] In addition to the method, the disclosure therefore also relates to a machining center. The machining center comprises at least one clamping device configured to clamp a blank to be machined, as well as at least one mechanical machining device comprising at least one mechanical machining tool, which is configured to machine a clamped blank.

[0046] Since the machining center is designed to produce at least one annular disk-shaped component from a blank to be machined according to a method as described above and thus to carry out the method described above, all statements in connection with the method apply analogously to the machining center.

[0047] The vertical plane with respect to which the blank can be clamped or is clamped at an angle is typically aligned perpendicular to a (horizontal) machining or machine axis of the machining center.

[0048] The invention is explained using exemplary embodiments in the drawings. In the drawings: Fig. 1 , 2 each a schematic representation of a blank clamped in a clamping situation according to an embodiment; and Fig. 3 , 4each a schematic diagram of a machining center used to carry out the method according to an embodiment.

[0049] The Fig. 1 , 2 each show a schematic diagram of a blank 1 clamped in a clamping situation AS according to an embodiment. The clamping of the blank 1 in the Fig. 1 , 2 The clamping situations AS shown take place within the scope of carrying out a method for producing an annular disc-shaped component 2. The component 2 to be produced is in particular a drive wheel for rail vehicles, ie a railway wheel, in particular a railway wheel for high-speed trains.

[0050] The method described in connection with the exemplary embodiments shown in the figures comprises the following steps: In a first step of the method, at least one blank 1 to be machined mechanically, i.e., by cutting, is provided. In the exemplary embodiments shown in the figures, the blank 1 has a rotationally symmetrical, annular disk-shaped geometry with a central recess 3. The central axis of the blank 1 is designated "ZA"; it can be seen that the central axis ZA of the blank 1 is also the axis of symmetry of the blank 1, designated "SA". The disk plane of the blank 1, which is aligned perpendicular to the central axis ZA and thus penetrated at a right angle by the central axis ZA of the blank 1, is designated "SE".

[0051] Typically, a metallic blank 1, e.g. a cast or forged part, is provided, and accordingly the component 2 to be manufactured is a metallic component.

[0052] The blank 1 is clamped in a first clamping situation AS1 in a second step of the process following the first step (cf. Fig. 1 ). The figure shows that the blank 1 is clamped in a clamping situation AS in which the central axis ZA of the blank 1 is at an angle to a vertical axis VA or plane VE (this can be defined, for example, by a vertical machine axis of a machining center 4 used to carry out the method) and thus (apart from a possible intersection point) lies outside a vertical axis VE or plane VE. The blank 1 is therefore arranged in the clamping situation AS in such a way that the central axis ZA of the blank 1 is at an angle to the vertical axis VA or plane VE and thus not parallel to the vertical axis VA or plane VE. The disk plane SE of the blank 1 is at an angle or tilted to a horizontal axis HA or plane HE in the clamping situation AS (this can be defined, for example, by a vertical machine axis of a machining center 4 used to carry out the method).be defined by a horizontal machine axis of a machining center 4 used to carry out the process).

[0053] As can be seen, in the exemplary embodiments shown in the figures, the blank 1 is clamped in such a way that the central axis ZA of the blank 1 is aligned at an angle α between 80 and 100°, specifically at an angle of 90°, relative to the vertical axis VA or plane VE. In the clamping situation AS, the central axis ZA of the blank 1 is aligned horizontally, and the disk plane SE of the blank 1 is aligned vertically. In the clamping situation AS, the central axis ZA of the blank 1 is thus typically aligned coaxially or concentrically to a machining axis BA of a machining center 4 used to carry out the method (cf. Fig. 3 , 4 ).

[0054] The described angularly inclined or tilted arrangement or orientation of the blank 1 relative to the vertical axis VA or plane VE results in a number of advantages for the mechanical machining of the blank 1 and thus for the production of the component 2 to be produced. These advantages consist in particular in the fact that an accumulation of material removal resulting from machining, i.e. in particular chips, and / or coolant on the blank 1 to be machined is made more difficult or even impossible. This also means that the cooling effect and thus the efficiency of the cooling of the blank 1 during its mechanical machining can be (significantly) improved, as the typically used coolant can only accumulate with difficulty or not at all on the blank 1, i.e. in particular on a surface of the blank 1 that is parallel to the disk plane SE of the blank 1, and heat up there.The mechanical machining process of the blank 1 can also be better observed (optically), thus also resulting in advantages with regard to a process monitoring system that is to be implemented or has been implemented.

[0055] In the exemplary embodiments shown in the figures, the blank 1 is clamped in the respective clamping situation AS by means of at least one clamping device 5 comprising a plurality of clamping elements 6, ie clamping jaws, ie, for example, a chuck, of a machining center 4 used to carry out the method. The clamping device 5 is thus configured to clamp the blank 1 in the described respective clamping situation AS.

[0056] In a third step of the method following the second step, the blank 1 clamped in the respective clamping situation AS is mechanically processed to produce the component 2. The mechanical processing of the blank 1 is based, in particular, on data relating to the final geometry of the component 2 to be manufactured, so that the component 2 is manufactured with a near-net shape or with an exact net shape. The mechanical processing of the blank 1 comprises at least one machining or cutting mechanical processing step. The mechanical processing of the blank 1 can be carried out at least by turning and / or milling, optionally supplemented by drilling.

[0057] The mechanical machining of the blank 1 is carried out by means of at least one mechanical machining device 8 of a machining center 4 used to carry out the method, comprising at least one mechanical machining tool 7, ie at least one turning and / or milling tool, optionally additionally a drilling tool (cf. Fig. 3 , 4 ). Depending on the specific design, a corresponding mechanical processing device 8 can be mounted movably in at least one degree of freedom of movement - this can be a translational degree of freedom of movement along at least one translation axis and / or a rotational degree of freedom of movement about at least one rotation axis - relative to the blank 1 clamped in the clamping situation AS. Corresponding degrees of freedom of movement or translational or rotational axes are shown in the Fig. 3 , 4 indicated by the axes x, y and z.

[0058] Based on the Fig. 1 , 2 It is evident that the or a blank 1 can be clamped in several different clamping situations AS. Each clamping situation AS is characterized by the fact that several clamping jaws of at least one clamping device 5 engage a section of the blank 1, forming a clamping of the blank 1. In this case, the blank 1, as shown in the Fig. 1 , 2 shown, in respective clamping situations AS such that the central axis ZA of the blank 1 is at an angle, i.e., perpendicular in the embodiments shown in the figures, to the vertical axis VA or plane VE. In each clamping situation AS, a specific, in particular exposed and thus mechanically machinable, section of the blank 1 is mechanically machined. Each clamping situation AS thus typically correlates with a specific machining situation BS of the blank 1.

[0059] Fig. 1 shows an exemplary first clamping situation in which a complete mechanical machining of the outer circumference of the blank 1, i.e. a lateral surface of the blank 1 forming the outer circumference, takes place (cf. the curly bracket indicating the machinable area). Such mechanical machining includes a mechanical machining of the blank 1 with respect to the annular disk-shaped geometry of the blank 1 axially with respect to the central axis ZA of the blank 1, so that the blank 1 is provided with a specific outer circumferential contour forming the running surfaces of a wheel to be manufactured, e.g. by turning and / or milling. By mechanically machining the blank 1 clamped in the first clamping situation, a machining of the outer contour or the lateral surface of the component 2 to be manufactured, i.e. the area of ​​the running surfaces of a wheel to be manufactured, takes place.

[0060] Fig. 1 shows that the blank 1 is clamped in the first clamping situation via clamping elements 6 engaging an axially shoulder-like, protruding portion 9 of the inner diameter of the blank 1. Clamping jaws engaging the inner diameter or a corresponding surface are used as clamping elements 6 for clamping the blank 1 in the first clamping situation. It is evident that several clamping jaws can be used, evenly distributed around the circumference and arranged in such a way that centering of the blank 1 is possible in the first clamping situation.

[0061] In the Fig. 1 In the first clamping situation shown, a complete mechanical machining of a surface of the blank 1 that lies parallel to the disk plane SE, i.e., for example, an upper or lower side of the blank 1, can also take place. Such mechanical machining includes axial mechanical machining of the blank 1 with respect to the annular disk-shaped geometry of the blank 1, so that the blank 1 is provided, in particular by drilling, e.g., with through holes or blind holes that pass through it axially. In addition, such mechanical machining can mean radial mechanical machining of the blank 1 with respect to the annular disk-shaped geometry of the blank 1, so that the blank 1 is provided, for example, with radially extending, in particular annular, depressions. A targeted change to the cross-sectional geometry of the blank 1 is possible.

[0062] Fig. 2 shows an exemplary second clamping situation of the blank 1, in which a complete mechanical machining of a surface of the blank 1 lying parallel to the disk plane SE, i.e., e.g., an upper or lower side of the blank 1, takes place or can take place (cf. the curly bracket indicating the machinable area). Such mechanical machining includes axial mechanical machining of the blank 1 with respect to the annular disk-shaped geometry of the blank 1, so that the blank 1 is formed with a hub. In addition, such mechanical machining can mean radial mechanical machining of the blank 1 with respect to the annular disk-shaped geometry of the blank 1, so that the blank 1 is provided, for example, with radially extending, in particular annular, recesses.

[0063] Fig. 2 shows that, in the exemplary second clamping situation, the blank 1 is clamped by means of clamping elements 6 engaging the outer circumference of the blank 1 or by means of a circumferential surface of the blank 1 forming the outer circumference. Clamping jaws engaging the outer circumference or the circumferential surface forming the outer circumference are used as clamping elements 6 for clamping the blank 1 in the exemplary second clamping situation. In particular, several clamping jaws arranged evenly distributed around the outer circumference can be used. The clamping jaws can be arranged such that centering of the blank 1 is possible in the second clamping situation.

[0064] The Fig. 1 , 2This shows that a blank 1 can be clamped and machined in several different clamping situations AS. Each clamping situation AS is correlated with a specific machining situation. In each clamping or machining situation, the exposed sections of the clamped blank 1 can be machined.

[0065] Fig. 3 shows a schematic diagram of a machining center 4 according to an exemplary embodiment that can be used or is used to carry out the method. The machining center 4 comprises a clamping device 5, which is set up to clamp a blank 1 to be machined in a clamping situation AS, in which the central axis ZA of the blank is at an angle to a vertical axis VA or plane VE, as well as at least one mechanical machining device 8 comprising at least one mechanical machining tool 7, i.e. at least one turning and / or milling tool, i.e. at least one turning and / or milling device, which is set up to mechanically machine a blank 1 clamped in the clamping situation AS. Also shown is an optional blank storage device 10, via which blanks 1 to be mechanically machined can be provided by means of the machining center 4. The blanks 1 can be fed to the blank storage device 10 via a, for example,The workpiece is removed from the handling device 11 designed as a single- or multi-axis handling robot and fed into a processing space 12 of the processing center 4, where it is clamped accordingly and machined.

[0066] Based on Fig. 3 It can be seen that the vertical axis VA or plane VE with respect to which raw parts 1 can be clamped or are clamped at an angle is typically aligned perpendicular to a (horizontal) machining or machine axis MA of the machining center 4.

[0067] Based on Fig. 3 It can further be explained that in the clamping situation shown there or a corresponding clamping situation, both a mechanical machining of a surface of the blank 1 that lies parallel to a central plane, i.e. for a ring-disk-shaped blank 1 parallel to a disk plane, i.e. e.g. an upper or lower surface of the blank 1, and a mechanical machining of the outer circumference of the blank 1 can take place. Sections of the blank 1 that cannot be machined or can be machined in the clamping situation can be mechanically machined after a rotating or turning movement of the sectionally mechanically machined blank 1. The sectionally mechanically machined blank 1 can therefore be moved, rotated or turned out of the clamping situation after mechanical machining in the clamping situation - this particularly involves a 180° rotation orTurning - and moved back to the (same) clamping situation and clamped again in order to then machine the remaining not yet machined gates. The blank 1 can then be clamped on the opposite section of the blank 1; the clamping elements 6 engage the opposite section of the blank 1 in the clamping situation when the blank 1 is clamped again, compared to the first or previous clamping in the clamping situation.

[0068] This may require suitable handling of the partially machined blank 1, which can be implemented, for example, via a handling device 11, i.e., in particular, a robot device. The handling device 11 can thus be configured to remove a partially machined blank 1 from the clamping position, rotate or turn it, and transfer it back to the (same) clamping position.

[0069] Fig. 4 shows a schematic diagram of a machining center 4 that can be used or is used to carry out the method according to a further embodiment. Fig. 4 In contrast to the embodiment according to Fig. 3 has several machining areas 12a, 12b, in each of which a mechanical machining of a blank 1 is possible. Obviously, each machining area 12a, 12b therefore has its own mechanical machining device 8.

[0070] Based on the Fig. 4 The exemplary embodiment shown can be explained by the fact that a blank 1 can be transferred from a first clamping situation AS or first machining situation, in which the central axis ZA of the blank 1 is at an angle to the vertical axis VA or plane VE, into at least one further clamping situation AS2 or further machining situation, in which the central axis ZA of the blank 1 is at an angle to the vertical axis VA or plane VE. This opens up the possibility of providing several blanks 1 and machining them at least partially simultaneously.

[0071] Based on the Fig. 4 shown machining center 4 comprising two separate machining areas 12a, 12b, it is clear that it is possible, for example, for a first blank 1 to be machined to be initially clamped in a first clamping situation AS1, in which the central axis ZA of the first blank 1 is at an angle to the vertical axis VA or plane VE, and to be machined in a first mechanical machining step in the first clamping situation AS1 (cf. Fig. 4 ). After completion of the first mechanical machining step, the first blank 1, which has already been machined in sections, can be transferred to a second clamping situation AS2 (different from the first clamping situation AS1), in which the central axis ZA of the first blank 1 is again at an angle to the vertical axis VA or plane V2, clamped in this second clamping situation, and transferred for mechanical machining in a second mechanical machining step. A second blank 1 to be machined can be clamped in the first clamping situation AS1 during or after clamping of the first blank 2 in the second clamping situation AS2 and machined in a first mechanical machining step in the first clamping situation AS1.After completion of the first mechanical machining step, the second blank 1, which has already been machined in sections, can be transferred to the second clamping situation AS2, clamped therein and mechanically machined in a second mechanical machining step. This typically only occurs when the first blank 1 has left the second clamping situation AS2, i.e. the second mechanical machining step of the first blank 1 in the second clamping situation AS2 has been completed. Consequently, a chronologically sequential mechanical machining of several blanks 1 in several clamping situations AS1, AS2, i.e. a machining of several blanks 1 in several clamping situations AS1, AS2 one after the other, can take place. The second mechanical machining step of the first blank 1 can take place at least partially simultaneously with the first mechanical machining step of the second blank 1 (and vice versa).

[0072] Furthermore, it is possible for a first blank 1 to be machined to first be clamped in a first clamping situation AS1, in which the central axis ZA of the first blank 1 is at an angle to the vertical axis VA or plane VE, and to be machined in a first mechanical processing step in the first clamping situation AS1. After completion of the first mechanical processing step, the blank 1, which has already been machined in sections, can be transferred to a second clamping situation AS2, in which the central axis ZA of the first blank 1 is again at an angle to the vertical axis VA or plane VE, clamped in this second clamping situation and machined in a second mechanical processing step. A second blank 1 to be machined can first be clamped in the second clamping situation AS2 and machined in a first mechanical processing step in the second clamping situation AS2.After completion of the first mechanical machining step of the first blank 1 in the first clamping situation and after completion of the first mechanical machining step of the second blank 1 in the second clamping situation AS2, the first blank 1 can be transferred to the second clamping situation AS2, clamped therein, and mechanically machined in a second mechanical machining step, and after completion of the first mechanical machining step of the second blank 1 in the second clamping situation AS2 and the first mechanical machining step of the first blank 1 in the first clamping situation AS1, the second blank 1 can be transferred to the first clamping situation AS1, clamped therein, and mechanically machined in a second mechanical machining step. Thus, simultaneous mechanical machining of the blanks 1 in the respective clamping situations AS1, AS2 can take place.The blanks 1 machined in the respective first machining steps can then swap their respective first clamping situations AS1, AS2 and, after being clamped in the respective second clamping situations AS1, AS2, can be subjected to the respective second mechanical machining steps. The first mechanical machining step of the first blank 1 can thus be performed simultaneously with the first mechanical machining step of the second blank 1. The second mechanical machining step of the first blank 1 can also be performed simultaneously with the second mechanical machining step of the second blank 1.

[0073] From the above explanations it follows that each clamping situation AS1, AS2 is assigned a machining device 8 which is set up to carry out a mechanical machining of a clamped blank 1 to be carried out in the respective clamping situation AS1, AS2 or the machining situation correlated therewith. The machining device 8 assigned to the respective clamping situation AS1, AS2 can for this purpose be mounted such that it can move in at least one degree of freedom of movement relative to the blank 1 clamped in the respective clamping situation AS1, AS2. In principle, however, it is alternatively or additionally also conceivable for the blank 1 clamped in the respective clamping situation AS1, AS2 to be movable in at least one degree of freedom of movement, i.e.a degree of freedom of movement along a translation axis and / or about a rotation axis, relative to the mechanical processing device 8 assigned to the respective clamping situation AS1, AS2.

[0074] The transfer of a blank 1, possibly already machined, from a first clamping situation AS1 to the second clamping situation AS2 (or vice versa) can be carried out via a process already described in connection with the Fig. 3 The handling device 11, which comprises one or more handling elements, mentioned in the exemplary embodiment shown, i.e., for example, a handling robot, can be used. The handling device 11 is thus configured to transfer a blank 1, possibly already machined, from the first clamping situation AS1 to the second clamping situation AS2 (or vice versa).

Claims

1. A method for producing at least one annular disc-shaped part (2) in the form of a hub-containing wheel for a rail vehicle, characterized by the steps: - providing at least one blank (1) having a central axis (ZA), having an annular disc-shaped geometry, to be machined, wherein the machined outer circumference of the blank (1) forms a later running surface of the component (2); - arranging or clamping the blank (1) in one or more clamping situations (AS), each containing a specific clamping position or clamping orientation of the blank (1), in which the central axis (ZA) of the blank (1) is angular to a vertical axis (VA), wherein the angle between the central axis (ZA) of the blank (1) clamped in the respective clamping situation (AS) and the vertical axis (VA) is between 80 and 100 °; - machining of the clamped blank (1) for the production of the annular disc-shaped component (2), wherein the raw part (1) is clamped in a first such clamping situation (AS1), in which the first clamping situation in a first machining step a complete machining of the outer circumference of the raw part (1) takes place, wherein the machining includes a machining of the raw part (1) axially in relation to the geometry of the raw part (1), wherein the raw part is provided by turning and / or milling with an outer circumference contour forming the treads of the wheel (2) to be manufactured, wherein the raw part (1) is clamped in the first clamping situation over an axially projecting or excluded portion (9) of an inner diameter of the raw part (1) attacking clamping jaws, and wherein In the first clamping situation (AS1) or in a second such clamping situation (AS2), which differs from the first clamping situation (AS1), in which the raw part (1) is clamped on the outer circumference or on a shell surface of the raw part (1) forming the outer circumference attacking clamping jaws, in a second machining step a complete machining of a surface of the raw part (1) lying parallel to a disk plane (SE) of the raw part (1) takes place, wherein the machining machining includes a machining of the raw part (1) carried out axially with respect to the geometry of the raw part (1), wherein an inner diameter or a region of an inner diameter of the raw part (1) is machined to form a hub of the component (1) to be manufactured.

2. The method of claim 1, wherein the blank (1) is clamped at least in the first clamping situation such that the central axis (ZA) of the blank (1) is aligned at an angle of 90° relative to the vertical axis (VA).

3. The method of any one of the preceding claims, wherein - the raw part (1) is first clamped in the first clamping situation (AS1) and machined in the first machining step, and wherein the raw part after completion of the first machining step from the first clamping situation (AS1) to the second clamping situation (AS2) is transferred, clamped in this and machined in the second machining step, and wherein - another blank (1) is clamped during or after clamping of the first blank (1) in the second clamping situation (AS2) in the first clamping situation (AS1) and is clamped in a first machining step at least partially in the first clamping situation (AS1), and after completion of the first machining step of the further blank (1) is clamped in the second or another clamping situation (AS2), in which the central axis (ZA) of the further blank (1) is angled to the vertical axis (VA), transferred, clamped in this and machined in a second machining step.

4. The method of claim 1 or 2, wherein - the raw part (1) is first clamped in the first clamping situation (AS1) and machined in the first machining step, and after completion of the first machining step is transferred to the second clamping situation (AS2), is clamped in this and machined in the second machining step, wherein - a further blank (1) is first clamped in the second clamping situation (AS2), clamped and machined in a first machining step at least partially in the second clamping situation (AS), wherein after completion of the first machining step of the first blank (1) in the first clamping situation (AS1) and the first machining step of the further blank (1) in the second clamping situation (AS2), the first blank (1) is transferred to the second clamping situation (AS2), clamped in this situation and machined in the second machining step, and wherein after completion of the first machining step of the further blank (1) in the second clamping situation (AS2) and the first machining step of the first blank (1) in the first clamping situation (AS1), the further blank (1) is transferred to the first clamping situation (AS1), in which it is clamped and machined in a second machining step.

5. The method of any one of the preceding claims, wherein a railway wheel is manufactured.

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